U.S. patent application number 17/253191 was filed with the patent office on 2021-09-09 for transformer.
The applicant listed for this patent is LG INNOTEK CO., LTD.. Invention is credited to Seok BAE, Yu Seon KIM, Jung Ki LEE, Soo Kwang YOON.
Application Number | 20210280366 17/253191 |
Document ID | / |
Family ID | 1000005639551 |
Filed Date | 2021-09-09 |
United States Patent
Application |
20210280366 |
Kind Code |
A1 |
YOON; Soo Kwang ; et
al. |
September 9, 2021 |
TRANSFORMER
Abstract
The present invention pertains to a transformer, and more
specifically, to a transformer which includes a primary coil unit
comprising wound conductive lines, and a secondary coil unit in
which conductive plates are stacked. The transformer according to
an embodiment of the present invention may include: a bobbin; a
core unit which is coupled to the bobbin along the outer side of
the bobbin; and a plurality of conductive plates which are inserted
into the bobbin and stacked in the thickness direction.
Inventors: |
YOON; Soo Kwang; (Seoul,
KR) ; KIM; Yu Seon; (Seoul, KR) ; BAE;
Seok; (Seoul, KR) ; LEE; Jung Ki; (Seoul,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LG INNOTEK CO., LTD. |
Seoul |
|
KR |
|
|
Family ID: |
1000005639551 |
Appl. No.: |
17/253191 |
Filed: |
June 14, 2019 |
PCT Filed: |
June 14, 2019 |
PCT NO: |
PCT/KR2019/007184 |
371 Date: |
December 17, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01F 27/2866 20130101;
H01F 5/02 20130101; H01F 27/29 20130101; H01F 27/325 20130101 |
International
Class: |
H01F 27/32 20060101
H01F027/32; H01F 27/29 20060101 H01F027/29; H01F 5/02 20060101
H01F005/02; H01F 27/28 20060101 H01F027/28 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 22, 2018 |
KR |
10-2018-0072082 |
Sep 18, 2018 |
KR |
10-2018-0111707 |
Claims
1. A transformer, comprising: a bobbin; a core part disposed
outside the bobbin to expose a portion of the bobbin; and a
plurality of conductive plates inserted into the bobbin, the
plurality of conductive plates being stacked in a thickness
direction, wherein the bobbin has therein openings to respectively
expose, among the plurality of conductive plates, a portion of an
upper surface of a conductive plate located at an uppermost
position in the thickness direction and a portion of a lower
surface of a conductive plate located at a lowermost position in
the thickness direction.
2. A transformer, comprising: a bobbin; a core part disposed
outside the bobbin to expose a portion of the bobbin; and a
plurality of conductive plates inserted into the bobbin, the
plurality of conductive plates constituting an upper coil part, a
middle coil part, and a lower coil part, wherein the bobbin
comprises: a lower receiving part receiving the lower coil part; a
middle receiving part disposed on the lower receiving part to
receive the middle coil part; and an upper receiving part disposed
on the middle receiving part to receive the upper coil part,
wherein the upper receiving part comprises a first protruding
portion covering at least a portion of an upper surface of an
uppermost conductive plate of the upper coil part, and wherein the
lower receiving part comprises a second protruding portion covering
at least a portion of a lower surface of a lowermost conductive
plate of the lower coil part.
3. The transformer according to claim 2, wherein the bobbin further
comprises: an upper connection part connecting the upper receiving
part and the middle receiving part; and a lower connection part
connecting the middle receiving part and the lower receiving
part.
4. The transformer according to claim 3, wherein the upper
receiving part comprises: a bottom portion that is in contact with
the upper connection part; a middle portion forming a sidewall of
the upper receiving part and extending upwards from at least a
region of an edge of an upper surface of the bottom portion; and a
top portion disposed along an upper surface of the middle
portion.
5. The transformer according to claim 4, wherein the first
protruding portion protrudes from the top portion.
6. The transformer according to claim 4, wherein outer side
surfaces of the bottom portion, the middle portion and the top
portion are aligned in a thickness direction.
7. The transformer according to claim 4, wherein an upper surface
of the top portion protrudes further inwards than a lower surface
thereof that is in contact with the middle portion when viewed in
plan.
8. The transformer according to claim 7, wherein an inner side
surface of the top portion is formed at an incline.
9. The transformer according to claim 7, wherein an inner side
surface of the top portion and an inner side surface of the middle
portion form an obtuse angle therebetween.
10. The transformer according to claim 8, wherein an edge of at
least a portion of an upper surface of an uppermost conductive
plate of the upper coil part is in contact with the inner side
surface of the top portion that is formed at an incline.
11. The transformer according to claim 1, wherein each of the
plurality of conductive plates comprises: a coil portion
corresponding to a winding of a secondary coil; and a first
connection portion and a second connection portion respectively
extending from both ends of the coil portion in one direction,
wherein the one direction has a predetermined inclination with
respect to a long-axis direction of the core part when viewed in
plan.
12. The transformer according to claim 11, wherein each of the
plurality of conductive plates comprises: a first boundary portion
between an outer side of one end of the coil portion and the first
connection portion; a second boundary portion between an inner side
of the one end and the first connection portion; a third boundary
portion between an inner side of another end of the coil portion
and the second connection portion; and a fourth boundary portion
between an outer side of the other end and the second connection
portion.
13. The transformer according to claim 12, wherein a curvature of
any one boundary portion among the first boundary portion to the
fourth boundary portion is greater than curvatures of three
remaining boundary portions.
14. The transformer according to claim 13, wherein the first
connection portion is connected to a ground terminal, wherein the
second connection portion is connected to a signal terminal, and
wherein the any one boundary portion having a curvature greater
than curvatures of the three remaining boundary portions is the
fourth boundary portion.
15. The transformer according to claim 11, wherein the plurality of
conductive plates comprises: a plurality of first type of
conductive plates; and a plurality of second type of conductive
plates having a planar shape that is bilaterally symmetrical with a
planar shape of the first type of conductive plates, and wherein
the plurality of first type of conductive plates and the plurality
of second type of conductive plates are alternately disposed.
16. The transformer according to claim 11, wherein the
predetermined inclination is less than 87 degrees.
17. The transformer according to claim 1, wherein each of the
plurality of conductive plates comprises: a coil portion
corresponding to a winding of a secondary coil, the coil portion
having an open annular planar shape; a first connection portion
extending from one end of the coil portion in a first direction;
and a second connection portion extending from another end of the
coil portion in a second direction different from the first
direction, and wherein the first direction and the second direction
form a predetermined angle therebetween when viewed in plan.
18. The transformer according to claim 17, wherein the
predetermined angle is between 3 degrees and 90 degrees.
19. The transformer according to claim 17, wherein the first
direction corresponds to a direction in which the plurality of
conductive plates is inserted into the bobbin.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a transformer including a
primary coil unit composed of wound conductive lines and a
secondary coil unit in which conductive plates are stacked.
BACKGROUND ART
[0002] Various coil components, such as a transformer and a line
filter, are mounted in a power supply unit of an electronic
device.
[0003] A transformer may be included in electronic devices for
various purposes. For example, a transformer may be used to perform
an energy transfer function of transferring energy from one circuit
to another circuit. In addition, a transformer may be used to
perform a voltage-boosting or voltage reduction function of
changing the magnitude of voltage. In addition, a transformer,
which has characteristics in which only inductive coupling is
exhibited between primary and secondary coils and thus no DC path
is directly formed, may be used to block direct current and apply
alternating current or to insulate between two circuits.
[0004] In general, a transformer uses a bobbin in order to maintain
an insulation distance between a primary coil, a secondary coil,
and a core, to protect respective components, and to fix the
positions of the components. In order to perform these functions, a
polymer-based material, such as PET, PBT or LCP, which has
excellent formability, processability, insulativity, and impact
resistance, is used for a bobbin. However, due to the
characteristics thereof, the polymer has notably poor heat transfer
properties compared to metal, and is thus disadvantageous in terms
of dissipation of heat from a core or a coil, in which
high-temperature heat is generated, resulting in deterioration in
the efficiency of a transformer. Specifically, current, other than
the current that is consumed when a transformer boosts or reduces
voltage, is lost and is converted into heat, and the heat is
released from a core and primary and secondary coils. For example,
in the case of a 3 kW transformer, when 1% loss occurs, 30 W of
heat is generated. In addition to efficiency, heat dissipation
performance is also an important performance index of a
transformer.
[0005] However, in general, because a transformer is configured
such that a lower portion of a core is in contact with a substrate
and an upper portion of the core is fixed to a metallic bracket,
the heat generated from primary and secondary coils is discharged
to the substrate or the bracket via the core. Therefore, it is
preferable for a bobbin to have a structure that enables the heat
generated from the primary and secondary coils to be easily
transferred to the core. Generally, the bobbin has a shape that
surrounds most of the secondary coil in order to secure an
insulation distance. Therefore, there is the need for a bobbin
capable of improving the heat dissipation performance of a
transformer.
[0006] Meanwhile, in recent years, according to the trend of
miniaturization and integration of various electronic devices,
there is a need to reduce the size of a transformer, which is a
power supply device. Also, research is underway toward the
implementation of a secondary coil using a metal plate in order to
satisfy high power performance while reducing the size thereof.
However, in order to realize a plurality of turns in a secondary
coil using a metal plate, methods of electrically connecting and
fixing a plurality of metal plates stacked in a thickness direction
are required. As one of these fixing methods, a soldering method
may be considered, but there is a problem in that the area of a
coil is so large that it is difficult to apply solder thereto, and
heat is dispersed due to the space between the metal plates,
whereby workability is deteriorated, and consequently, productivity
is reduced. In addition, metal plates constituting a secondary coil
have connection portions extending from portions functioning as a
coil for connection with external parts, but there is a problem in
that a current concentration phenomenon occurs at boundaries with
the connection portions.
DISCLOSURE
Technical Problem
[0007] The present disclosure has been made in order to solve the
above problems with the conventional art, and provides a
transformer including a bobbin capable of efficiently dissipating
heat.
[0008] In addition, the present disclosure provides a transformer
capable of securing fixability of a secondary coil unit and a
core.
[0009] In addition, the present disclosure provides an efficient
connection structure of a secondary coil unit in which a plurality
of metal plates is stacked.
[0010] In addition, the present disclosure provides a transformer
capable of alleviating a current concentration phenomenon of a
secondary coil unit.
[0011] The objects to be accomplished by the disclosure are not
limited to the above-mentioned objects, and other objects not
mentioned herein will be clearly understood by those skilled in the
art from the following description.
Technical Solution
[0012] In order to accomplish the above objects, a transformer
according to an embodiment of the present disclosure structurally
compensates for poor heat dissipation caused by use of a bobbin
made of a polymer material having excellent insulativity.
[0013] To this end, a transformer according to an embodiment may
include a bobbin, a core part disposed outside the bobbin to expose
a portion of the bobbin, and a plurality of conductive plates
inserted into the bobbin, the plurality of conductive plates being
stacked in a thickness direction. The bobbin may have therein
openings to respectively expose, among the plurality of conductive
plates, a portion of the upper surface of the conductive plate
located at the uppermost position in the thickness direction and a
portion of the lower surface of the conductive plate located at the
lowermost position in the thickness direction.
[0014] In addition, a transformer according to an embodiment may
include a bobbin, a core part disposed outside the bobbin to expose
a portion of the bobbin, and a plurality of conductive plates
inserted into the bobbin, the plurality of conductive plates
constituting an upper coil part, a middle coil part, and a lower
coil part. The bobbin may include a lower receiving part receiving
the lower coil part, a middle receiving part disposed on the lower
receiving part to receive the middle coil part, and an upper
receiving part disposed on the middle receiving part to receive the
upper coil part. The upper receiving part may include a first
protruding portion covering at least a portion of the upper surface
of the uppermost conductive plate of the upper coil part, and the
lower receiving part may include a second protruding portion
covering at least a portion of the lower surface of the lowermost
conductive plate of the lower coil part.
[0015] For example, the bobbin may further include an upper
connection part connecting the upper receiving part and the middle
receiving part and a lower connection part connecting the middle
receiving part and the lower receiving part.
[0016] For example, the upper receiving part may include a bottom
portion that is in contact with the upper connection part, a middle
portion forming a sidewall of the upper receiving part and
extending upwards from at least a region of the edge of the upper
surface of the bottom portion, and a top portion disposed along the
upper surface of the middle portion.
[0017] For example, the first protruding portion may protrude from
the top portion.
[0018] For example, the outer side surfaces of the bottom portion,
the middle portion and the top portion may be aligned in the
thickness direction.
[0019] For example, the upper surface of the top portion may
protrude further inwards than the lower surface thereof that is in
contact with the middle portion when viewed in plan.
[0020] For example, the inner side surface of the top portion may
be formed at an incline.
[0021] For example, the inner side surface of the top portion and
the inner side surface of the middle portion may form an obtuse
angle therebetween.
[0022] For example, the edge of at least a portion of the upper
surface of the uppermost conductive plate of the upper coil part
may be formed at an incline.
[0023] In addition, a transformer according to still another
embodiment may include a bobbin, a core part coupled to the bobbin
along the outer side of the bobbin, and a plurality of conductive
plates inserted into the bobbin, the plurality of conductive plates
being stacked in a thickness direction, and each of the plurality
of conductive plates including a coil portion corresponding to a
winding of a secondary coil, and a first connection portion and a
second connection portion respectively extending from both ends of
the coil portion in one direction. The one direction may have a
predetermined inclination with respect to a long-axis direction of
the core part when viewed in plan.
[0024] For example, each of the plurality of conductive plates may
include a first boundary portion between the outer side of one end
of the coil portion and the first connection portion, a second
boundary portion between the inner side of the one end and the
first connection portion, a third boundary portion between the
inner side of the other end of the coil portion and the second
connection portion, and a fourth boundary portion between the outer
side of the other end and the second connection portion.
[0025] For example, the curvature of any one boundary portion among
the first boundary portion to the fourth boundary portion may be
greater than the curvatures of three remaining boundary
portions.
[0026] For example, the first connection portion may be connected
to a ground terminal, the second connection portion may be
connected to a signal terminal, and the any one boundary portion
having a curvature greater than the curvatures of the three
remaining boundary portions may be the fourth boundary portion.
[0027] For example, the plurality of conductive plates may include
a plurality of first type of conductive plates and a plurality of
second type of conductive plates having a planar shape that is
bilaterally symmetrical with the planar shape of the first type of
conductive plates, and the plurality of first type of conductive
plates and the plurality of second type of conductive plates may be
alternately disposed.
[0028] For example, the predetermined inclination may be less than
87 degrees.
[0029] In addition, a transformer according to still another
embodiment may include a bobbin, a core part coupled to the bobbin
along the outer side of the bobbin, and a plurality of conductive
plates inserted into the bobbin, the plurality of conductive plates
being stacked in a thickness direction, and each of the plurality
of conductive plates including a coil portion corresponding to a
winding of a secondary coil, the coil portion having an open
annular planar shape, a first connection portion extending from one
end of the coil portion in a first direction, and a second
connection portion extending from the other end of the coil portion
in a second direction different from the first direction. The first
direction and the second direction may form a predetermined angle
therebetween when viewed in plan.
[0030] For example, the predetermined angle may be between 3
degrees and 90 degrees.
[0031] For example, the first direction may correspond to a
direction in which the plurality of conductive plates is inserted
into the bobbin.
[0032] For example, the plurality of conductive plates may include
a plurality of first type of conductive plates and a plurality of
second type of conductive plates having a planar shape that is
bilaterally symmetrical with the planar shape of the first type of
conductive plates, and the plurality of first type of conductive
plates and the plurality of second type of conductive plates may be
alternately disposed.
Advantageous Effects
[0033] The effects of a transformer according to the present
disclosure will be described below.
[0034] First, an insulation distance between a secondary coil and a
primary coil may be secured, and at the same time, heat dissipation
performance of the secondary coil may be improved.
[0035] Second, the present disclosure is capable of securing
fixability of the secondary coil unit while maintaining heat
dissipation performance.
[0036] Third, a plurality of metal plates constituting the
secondary coil may be efficiently engaged.
[0037] Fourth, the present disclosure is capable of alleviating a
current concentration phenomenon of the secondary coil unit.
[0038] The effects achievable through the disclosure are not
limited to the above-mentioned effects, and other effects not
mentioned herein will be clearly understood by those skilled in the
art from the following description.
DESCRIPTION OF DRAWINGS
[0039] The accompanying drawings are included to provide a further
understanding of the disclosure and illustrate embodiments of the
disclosure together with the detailed description. However, the
technical features of the disclosure are not limited to specific
drawings, and the features shown in the drawings may be combined to
construct a new embodiment.
[0040] FIG. 1 is a perspective view showing an example of a
transformer according to an embodiment of the present
disclosure.
[0041] FIG. 2 is an exploded perspective view showing an example of
a transformer according to an embodiment of the present
disclosure.
[0042] FIGS. 3A to 3J show the shapes of bobbins according to
embodiments of the present disclosure.
[0043] FIG. 4 is a perspective view showing the external appearance
of an example of a lower core according to the embodiment.
[0044] FIG. 5 shows the planar shapes of two types of conductive
plates according to the embodiment.
[0045] FIG. 6 is a view showing engagement of conductive plates
according to an embodiment of the present disclosure.
[0046] FIG. 7 is a cross-sectional view showing an example of a
bobbin structure to which a heat dissipation unit according to
another embodiment of the present disclosure is applied.
[0047] FIG. 8 is a perspective view showing an example of a
transformer 100 according to still another embodiment of the
present disclosure.
[0048] FIG. 9 is an exploded perspective view showing an example of
a clip-coupled transformer according to still another embodiment of
the present disclosure.
[0049] FIGS. 10A and 10B are respectively a side view and a front
view of a bobbin according to still another embodiment of the
present disclosure.
[0050] FIG. 11A is a plan view of a core part according to still
another embodiment.
[0051] FIG. 11B is a perspective view of the external appearance of
an example of a lower core.
[0052] FIGS. 12A and 12B show the respective planar shapes of two
types of conductive plates according to still another
embodiment.
[0053] FIG. 13A is an exploded perspective view showing the
configuration of a secondary coil unit according to still another
embodiment.
[0054] FIG. 13B is a perspective view showing engagement of a
plurality of conductive plates.
[0055] FIG. 13C is a plan view of the plurality of conductive
plates shown in FIG. 13B.
[0056] FIGS. 14A and 14B show the respective planar shapes of two
types of conductive plates according to still another
embodiment.
[0057] FIG. 14C is a plan view showing engagement of the conductive
plates shown in FIGS. 14A and 14B.
[0058] FIGS. 14D and 14E show the respective planar shapes of two
types of conductive plates according to still another
embodiment.
[0059] FIG. 14F is a plan view showing engagement of the conductive
plates shown in FIGS. 14D and 14E.
[0060] FIG. 15 is a view showing engagement of conductive plates
according to still another embodiment of the present
disclosure.
[0061] FIGS. 16A and 16B are views showing engagement of conductive
plates and a bobbin according to still another embodiment of the
present disclosure.
[0062] FIG. 17 shows an example of engagement of conductive plates
according to still another embodiment of the present
disclosure.
BEST MODE
[0063] Hereinafter, devices and methods to which embodiments of the
present disclosure are applied will be described in detail with
reference to the accompanying drawings. The suffixes "module" and
"unit" used herein to describe configuration components are
assigned or used in consideration only of convenience in creating
this specification, and the two suffixes themselves do not have any
distinguished meanings or roles from each other.
[0064] In the following description of the embodiments, it will be
understood that, when each element is referred to as being formed
"on" or "under" and "ahead of" or "behind" another element, it can
be directly "on" or "under" and "ahead of" or "behind" the other
element, or can be indirectly formed with one or more intervening
elements therebetween.
[0065] Additionally, terms such as "first", "second", "A", "B",
"(a)", "(b)", etc. may be used herein to describe the components of
the embodiments. These terms are only used to distinguish one
element from another element, and the essence, order, or sequence
of corresponding elements is not limited by these terms. It should
be noted that if it is described in the specification that one
component is "connected", "coupled", or "joined" to another
component, the former may be directly "connected", "coupled", or
"joined" to the latter, or may be indirectly "connected",
"coupled", or "joined" to the latter via another component.
[0066] Additionally, the term "comprises", "includes", or "has"
described herein should be interpreted not to exclude other
elements but to further include such other elements since the
corresponding elements may be inherent unless mentioned otherwise.
Unless otherwise defined, all terms used herein, which include
technical or scientific terms, have the same meanings as those
generally appreciated by those skilled in the art. Terms such as
those defined in common dictionaries should be interpreted as
having the same meanings as terms in the context of the pertinent
technology, and should not be interpreted as having ideal or
excessively formal meanings unless clearly defined in the
specification.
[0067] Hereinafter, a transformer according to the embodiment will
be described in more detail with reference to the accompanying
drawings.
[0068] FIG. 1 is a perspective view showing an example of a
transformer 100 according to an embodiment of the present
disclosure, and FIG. 2 is an exploded perspective view showing an
example of a transformer according to an embodiment of the present
disclosure.
[0069] Referring to FIGS. 1 and 2, a transformer 100 according to
an embodiment of the present disclosure may include a bobbin 110, a
plurality of conductive plates 120 inserted into the bobbin 110, a
plurality of engaging parts 130 electrically connecting the
plurality of conductive plates 120 so as to constitute a secondary
coil unit together with the plurality of conductive plates 120 in
an integral form, and a core part 140 coupled to the outer side of
the bobbin 110 so as to surround at least a portion of the bobbin
110.
[0070] Here, the transformer 100 according to the embodiment may
further include a conductive wire wound on the bobbin 110 to
constitute a primary coil unit, but an illustration thereof is
omitted in the drawings of this specification. The primary coil
unit (not shown) may take a multiple-winding form, in which a rigid
conductive metal, e.g. a copper conductive wire, is wound several
times, or a plate form.
[0071] The secondary coil unit 120 and 130 may transform and output
a power signal received from the primary coil unit (not shown). In
FIG. 1, the secondary coil unit 120 and 130 may be configured such
that a total of sixteen conductive plates is stacked in a thickness
direction (e.g. a z-axis direction). Each conductive plate may
correspond to one turn in the secondary coil unit. That is, when
sixteen conductive plates are used, the number of turns in the
secondary coil unit may be sixteen, but this is merely given by way
of example. A greater or smaller number of conductive plates may be
used. In this case, the number of turns in the secondary coil unit
may be proportional to the number of conductive plates.
[0072] For example, each of the plurality of conductive plates 120
may be inserted into the bobbin 110 in a direction parallel to the
x-axis.
[0073] The plurality of conductive plates 120 may be electrically
insulated from each other by insulation materials, except for
electrical connection via the engaging parts 130. For example, an
insulation film may be disposed between adjacent conductive plates
among the plurality of conductive plates in order to electrically
insulate the conductive plates from each other. The insulation film
may include components such as ketone and polyimide, without being
necessarily limited thereto. The conductive plates 120 may include
an upper coil part 121, a middle coil part 123, and a lower coil
part 125. The coil parts 121, 123 and 125 may be spaced apart from
each other in the thickness direction.
[0074] In addition, the plurality of conductive plates 120 may
include a conductive metal, e.g. copper, without being necessarily
limited thereto. For example, the plurality of conductive plates
may include aluminum. When aluminum is used instead of copper, the
thickness of each conductive plate may be approximately 60% greater
than when copper is used, but this thickness ratio is not
limiting.
[0075] The bobbin 110 may have a shape suitable for insulating the
conductive wires (not shown) constituting the primary coil unit,
the plurality of conductive plates 120 constituting the secondary
coil unit, and the core part 140 from each other while
accommodating or fixing at least a portion of each of the
components 120 and 140.
[0076] The bobbin 110 may include an insulation material, e.g. a
resin material, and may be produced through a molding method. The
bobbin 110 according to the embodiments of the present disclosure
may have openings for respectively exposing a portion of the upper
surface of the conductive plate located at the uppermost position
in the thickness direction and a portion of the lower surface of
the conductive plate located at the lowermost position in the
thickness direction, among the plurality of conductive plates 120.
The more concrete shape of the bobbin 110 will be described later
with reference to FIGS. 3A to 3I.
[0077] The engaging parts 130 may have a metal bar shape, may
penetrate one end portion of each of the conductive plates 120 in
the thickness direction (e.g. the Z-axis direction), and may be
fixed to each of the conductive plates 120 through a soldering
method. Of course, in some embodiments, the metal bar may be
replaced with other fastening members such as bolts, nuts, and
washers.
[0078] The core part 140, which has the characteristics of a
magnetic circuit, may serve as a path for magnetic flux. The core
part may include an upper core 141 coupled from the upper side and
a lower core 142 coupled from the lower side. The two cores 141 and
142 may have shapes that are vertically symmetrical with each
other, or may have shapes that are vertically asymmetrical with
each other. The core part 140 may include a magnetic material, e.g.
iron or ferrite, without being necessarily limited thereto. The
concrete shape of the core part 140 will be described later with
reference to FIG. 4.
[0079] FIGS. 3A to 3J show the shapes of bobbins according to
embodiments of the present disclosure.
[0080] First, referring to FIGS. 3A and 3B, a bobbin 110A according
to an embodiment may include an upper receiving part 111A, a middle
receiving part 113, a lower receiving part 115A, an upper
connection part 112 connecting the upper receiving part 111A and
the middle receiving part 113, a lower connection part 114
connecting the middle receiving part 113 and the lower receiving
part 115A, and a winding-fixing part 117.
[0081] Except for the winding-fixing part 117, each of the
receiving parts 111A, 113 and 115A may have a "U"-shaped planar
shape or a track-shaped planar shape in which one semicircular
portion is cut off. Each of the receiving parts 111A, 113 and 115A
and the two connection parts 112 and 114 may be aligned in the
vertical direction about a through-hole TH when viewed in plan.
Further, the inner surface of each of the connection parts 112 and
114 may define the sidewall of the through-hole TH. The
through-hole TH may have a track-shaped planar shape, but this is
merely given by way of example, and there is no problem as long as
the through-hole TH has a shape corresponding to the planar shape
of a central leg of the core part 140 to be described later.
[0082] Each of the receiving parts 111A, 113 and 115A has a
receiving hole, for receiving the conductive plate 120, and an
opening, through which the conductive plate 120 is inserted and
which is formed in the other side thereof that is opposite one side
thereof, which has a semicircular shape in the X-Y plane. Here, the
upper receiving part 111A and the lower receiving part 115A are
formed to be vertically symmetrical with each other in the
thickness direction (e.g. the Z-axis direction) such that the upper
receiving part 111A is open upwards and the lower receiving part
111C is open downwards. Accordingly, at least a portion of the
conductive plate located at the uppermost position in the upper
coil part 121 received in the upper receiving part 111A is exposed
in the upward direction, and at least a portion of the conductive
plate located at the lowermost position in the lower coil part 125
received in the lower receiving part 115A is exposed in the
downward direction. Accordingly, each of the upper coil part 121
and the lower coil part 125 has an increased heat dissipation area
in at least one surface thereof, with the result that, depending on
the position of the exposed surface, heat is rapidly transferred to
the ambient air or to the core part 140 when the core part 140 is
coupled thereto, thereby exhibiting advantageous heat dissipation
effects.
[0083] Unlike the upper receiving part 111A and the lower receiving
part 115A, the middle receiving part 113 may have an opening formed
in the X-axis direction, but may not have an opening in the
upward-downward direction, except for the through-hole TH. The
purpose of this is to secure an insulation distance between the
middle coil part 123 to be received in the middle receiving part
113 and the primary coil unit to be wound around the upper
connection part 112 and the lower connection part 114.
[0084] The conductive wire (not shown) constituting the primary
coil unit may be wound around the outer surface of the upper
connection part 112 in the space between the upper receiving part
111A and the middle receiving part 130 and the outer surface of the
lower connection part 114 in the space between the middle receiving
part 113 and the lower receiving part 115A. The winding-fixing part
117 may include two holes 117H extending in the thickness
direction, and one end and the other end of the conductive wire
(not shown) constituting the primary coil unit may be fixedly
fitted into the respective holes 117H.
[0085] Next, portion `A` in FIG. 3B will be described in detail
with reference to FIG. 3C.
[0086] Referring to FIG. 3C, the upper receiving part 111A may
include a bottom portion 111A_B, a middle portion 111A_S, and a top
portion 111A_T. The outer surfaces of the bottom portion 111A_B,
the middle portion 111A_S, and the top portion 111A_T may be
aligned with each other in the thickness direction.
[0087] The middle portion 111A_S has a predetermined thickness t
and a predetermined height h1, and forms the sidewall of the upper
receiving part 111A. The middle portion 111A_S extends upwards from
the upper surface of the bottom portion 111A_B along the edge of at
least a region thereof (e.g. a region other than the opening formed
in the X-axis direction) so as to have a "U"-shaped planar shape.
The lower surface of the bottom portion 111A_B is connected to the
upper connection part 112.
[0088] The lower surface of the top portion 111A_T may be in
contact with the upper surface of the middle portion 111A_S, and
may have the same planar shape as the upper surface of the middle
portion 111A_S. In addition, the top portion 111A_T may have a
trapezoidal cross-sectional shape, and thus the upper surface of
the top portion 111A_T may protrude further inwards (i.e. toward
the through-hole TH) than the lower surface thereof that is in
contact with the middle portion 111A_S. Therefore, the inner side
surface between the upper surface and the lower surface of the top
portion 111A_T may be formed at an incline. In this case, it is
preferable that the angle .theta. formed between the inner side
surface of the middle portion 111A_S and the inner side surface of
the top portion 111A_T be an obtuse angle. That is, the top portion
111A_T may have a protruding portion formed in an area that does
not overlap the middle portion 111A_S in the thickness direction
(e.g. the z-axis direction). In this case, the cross-sectional
shape of the protruding portion may be a right triangle, and the
angle .theta. formed between the inner side surface of the middle
portion 111A_S and the inner side surface of the top portion 111A_T
may correspond to one external angle of the right triangle, which
is formed by the cross-sectional shape of the protruding portion.
In addition, the region of the top portion 111A_T, other than the
protruding portion, may have a rectangular cross-sectional shape.
The upper surface of the bottom portion 111A_B, the inner side
surface of the middle portion 111A_S, and the inclined inner side
surface of the top portion 111A_T may define a receiving hole in
the upper receiving part 111A, in which the upper coil part 121 is
received.
[0089] In conclusion, the opening that upwardly exposes at least a
portion of the upper surface of the conductive plate disposed at
the uppermost position in the upper coil part 121 may be defined by
the shape of the upper surface of the top portion 111A_T.
[0090] Meanwhile, the height h1 of the middle portion 111A_S may be
smaller than the height of the upper coil part 121 received in the
receiving hole in the upper receiving part 111A. In this case, due
to the inclined inner side surface of the top portion 111A_T, when
the upper coil part 121 is received in the receiving hole in the
upper receiving part 111A, the edge of the upper surface of the
uppermost conductive plate of the upper coil part 121 comes into
contact with a portion B of the inner side surface of the top
portion 111A_T.
[0091] Due to this structure, even if a tolerance occurs in a
manner such that the gap in the thickness direction between the
conductive plates increases, the conductive plates are pressed by
the inclined inner side surface of the top portion 111A_T, making
it possible to accommodate the tolerance and to facilitate
insertion of the coil part into the receiving hole in the
manufacturing process. In addition, since the edge of the upper
surface of the uppermost conductive plate of the upper coil part
121 is in point or line contact with the inner side surface of the
top portion 111A_T, as shown in FIG. 3D, the entirety of the upper
surface of the uppermost conductive plate may be substantially
directly exposed to the air, and accordingly, the heat dissipation
area may be maximized.
[0092] Further, even if the conductive wire (not shown)
constituting the primary coil unit is also located on a region of
the lower surface of the bottom portion 111A_B that overlaps the
middle portion 111A_S in the thickness direction, the shortest
insulation distance between the conductive wire and the upper coil
part 121 increases from "h2+w1" by the distance between the inner
edge of the upper surface of the top portion 111A_T and the point
B. Accordingly, this configuration also exhibits effects of
securing an additional insulation distance.
[0093] Meanwhile, the gap w2 between the upper coil part 121 and
the inner side surface of the middle portion 111A_S may depend on
the processing tolerances of the bobbin 110A and each of the
conductive plates constituting the upper coil part 121. For
example, although there is a difference depending on the kind of
material, assuming that the tolerance of the bobbin 110A is .+-.0.2
mm and the tolerance of the conductive plate is .+-.0.1 mm, the gap
w2 between the upper coil part 121 and the inner side surface of
the middle portion 111A_S may be up to 0.3 mm. However, the upper
coil part 121 needs to be fixed in the state of being in contact
with the point B of the bobbin 110A. To this end, the width w1 of
the upper surface of the top portion 111A_T needs to be greater
than at least `w2+t`, so it is preferable to satisfy the condition
`w1>w2+t`.
[0094] Further, the height h2 of the upper receiving part 111A is
the sum of the heights of the bottom portion 111A_B, the middle
portion 111A_S, and the top portion 111A_T. Therefore, assuming
that the height h2 of the upper receiving part 111A is fixed, when
the gap w2 between the upper coil part 121 and the inner side
surface of the middle portion 111A_S decreases, the value of
.theta. approaches 90 degrees. However, since the angle .theta. is
one external angle of the right triangle corresponding to the
region of the top portion 111A_T that protrudes toward the
through-hole TH, the value of .theta. exceeds 90 degrees at all
times. Further, even if the height h1 of the middle portion 111A_S
is infinitely small, the value of .theta. is less than 180 at all
times.
[0095] Consequently, the value of .theta. may have a range of
`90<.theta.<180`.
[0096] Further, the height h3 of the upper coil part 121 is greater
than the height h1 of the middle portion 111A_S at all times, and
as the height h1 of the middle portion 111A_S increases, the width
w1 of the upper surface of the top portion 111A_T also needs to
increase in order to remain in contact with the point B. However,
the height h1 of the middle portion 111A_S is less than the height
h3 of the upper coil part 121 at all times, and the height h3 of
the upper coil part 121 depends on the thickness of the individual
conductive plate. Therefore, assuming that the height h3 of the
upper coil part 121 is 4 mm, the height h1 of the middle portion
111A_S needs to be less than 4 mm. In the state in which the gap w2
between the upper coil part 121 and the inner side surface of the
middle portion 111A_S is maintained at 0.3 mm, as the value of
.theta. approaches 90, the width w1 of the upper surface of the top
portion 111A_T continuously increases, and at some point, the top
portion 111A_T comes into contact with the top portion (not shown)
that is located opposite the top portion 111A_T in the y-axis
direction. This means that the opening in the upper receiving part
111A of the bobbin 110A, which is open in the upward direction, is
not present, so it is difficult to expect heat dissipation
effect.
[0097] Therefore, in order to achieve the intended heat dissipation
function and the function of fixing the upper coil part 121 through
contact with the point B, it is preferable for the width w1 of the
upper surface of the top portion 111A_T to have a size for
preventing the upper coil part from being separated upwards through
the opening while minimally shielding the upper surface of the
uppermost conductive plate of the upper coil part 121.
Specifically, when the upper coil part 121 is assembled with the
upper receiving part 111A, a gap w2 attributable to the
above-mentioned tolerances is formed at each of both sides, and
thus the length (i.e. w1-t) of the region of the top portion 111A_T
that protrudes toward the through-hole TH may be twice the gap w2
between the upper coil part 121 and the inner side surface of the
middle portion 111A_S in order to prevent separation of the upper
coil part 121. For example, assuming that the thickness t of the
middle portion 111A_S is 0.8 mm and the gap w2 between the upper
coil part 121 and the inner side surface of the middle portion
111A_S is 0.3 mm, the width w1 of the upper surface of the top
portion 111A_T may be 1.4 mm, which is `t+2*w2`. Of course, the
thickness and the gap mentioned above are merely given by way of
example, and it will be apparent to those skilled in the art that
various changes in the thickness and the gap may be made depending
on the designed size of the transformer 100.
[0098] Although the upper receiving part 111A has been described
with reference to FIGS. 3C and 3D, the description of the upper
receiving part 111A may identically apply to the lower receiving
part 115A, except that the upper receiving part 111A and the lower
receiving part 115A are vertically symmetrical with each other.
[0099] Next, according to another aspect of the present embodiment,
the shape of the top portion 111A_T in the bobbin 110A shown in
FIG. 3C may be replaced with a different shape. This will be
described with reference to FIGS. 3E to 3H.
[0100] First, as shown in FIG. 3E, a bobbin 110B according to
another aspect of the present embodiment may include, rather than
the top portion 111A_T described above with reference to FIG. 3C, a
fixing portion 111B_PT, which protrudes from a region of the upper
surface of the sidewall of an upper receiving part 111B toward the
through-hole TH when viewed in plan. For example, the fixing
portion 111B_PT may have a rectangular column shape, and may extend
toward the through-hole TH from the center of a portion having a
semicircular planar shape, among the upper surface of the sidewall
of the upper receiving part 111B. Due to the arrangement of the
fixing portion 111B_PT, it is possible not only to prevent
separation of the upper coil part 121 when the upper coil part 121
is received, but also to secure the heat dissipation area of the
conductive plate located at the uppermost position in the upper
coil part 121.
[0101] Further, as shown in FIG. 3F, a bobbin 110C according to
still another aspect of the present embodiment may include a
plurality of fixing portions 111C_PT.
[0102] In this case, in each of the fixing portions 111B_PT and
111C_PT shown in FIGS. 3E and 3F, it is preferable for one side
surface oriented toward the through-hole TH to extend (for example,
parallel to the axis C in FIG. 3F) so as to contact one side
surface of the core part 140, which faces the one side surface of
each of the fixing portions when the core part 140 is coupled to
the bobbin 110B or 110C. Due thereto, each of the fixing portions
111B_PT and 111C_PT may secure fixability of the core part 140
together with the coil part.
[0103] According to still another aspect of the present embodiment,
as shown in FIG. 3G, a bobbin 110D may include a fixing portion
111D_CM having an arc-shaped planar shape. Also, in this case, as
shown in FIG. 3H, it is preferable for a straight side surface of
the fixing portion 111D_CM to extend so as to contact one side
surface of the core part 140, which faces the straight side surface
of the fixing portion when the core part 140 is coupled to the
bobbin 110D.
[0104] Meanwhile, the middle receiving part of the bobbin may be
modified in order to fix the core part 140. This will be described
with reference to FIGS. 3I and 3J.
[0105] Referring to FIG. 3I, a bobbin 110A' including a middle
receiving part 113A', which is a modification of the middle
receiving part of the bobbin 110A shown in FIGS. 3A and 3B, is
illustrated. Specifically, fixing portions 119 may be disposed at
both sides of the middle receiving part 113A' so as to extend from
the curved surfaces adjacent to the winding-fixing part 117 among
the outer side wall of the middle receiving part 113A' in a
direction (e.g. the Y-axis direction) intersecting the direction in
which the secondary coil unit is inserted (e.g. the X-axis
direction). Also, in this case, as shown in FIG. 3J, it is
preferable for one side surface of each of the fixing portions 119
to extend so as to contact one side surface of the core part 140,
which faces the one side surface of each of the fixing portions 119
when the core part 140 is coupled to the bobbin 110A'.
[0106] Although the upper receiving parts 111A, 111B, 111C and 111D
have been described above with reference to FIGS. 3A to 3I, since
the lower receiving parts 115A, 115B, 115C and 115D are vertically
symmetrical with the upper receiving parts 111A, 111B, 111C and
111D, the components including the fixing portions 111B_PT, 111C_PT
and 111D_CM may be similarly applied to the lower receiving parts
115A, 115B, 115C and 115D.
[0107] Next, the configuration of the core part 140 will be
described with reference to FIG. 4. FIG. 4 is a perspective view
showing the external appearance of an example of a lower core.
Although a lower core 142 of the core part 140 will be described
with reference to FIG. 4, the following description may also apply
an upper core 141 on the assumption that the upper core 141 is
vertically symmetrical with the lower core 142.
[0108] Referring to FIG. 4, the lower surface of the lower core 142
may have a rectangular planar shape including a long side extending
in one direction (e.g. the Y-axis direction) and a short side
extending in another direction (e.g. the X-axis direction)
intersecting the one direction.
[0109] In addition, the lower core 142 may include a central leg
142_1 (or a central portion) having a track-shaped column shape and
side portions 142_2 disposed at both sides of the lower core 142
that face each other around the central leg 142_1. In this case, in
order to couple the lower core 142 to the bobbin 110 in the form of
surrounding the bobbin 110, a receiving hole may be formed to have
a track-shaped planar shape by cutting off an area between the
inner side surfaces of the side portions 142_2 and the side surface
of the central leg 142_1, and may correspond to the size and shape
of the bobbin 110. This type of core is referred to as an "EPC"
core.
[0110] Meanwhile, the central leg 142_1 may be inserted into the
through-hole TH in the bobbin 110. In addition, when coupled to the
bobbin 110, the central leg (not shown) of the upper core 141 and
the central leg 142_1 of the lower core 142 may come into contact
with each other, or may be spaced apart from each other by a
predetermined distance (e.g. 100 .mu.m).
[0111] Next, the configuration of a plurality of conductive plates
constituting the secondary coil unit will be described with
reference to FIGS. 5 and 6.
[0112] FIG. 5 shows the planar shapes of two types of conductive
plates according to the embodiment.
[0113] First, referring to FIG. 5, two types of conductive plates
120A and 120B having different planar shapes are illustrated. Since
the first type of conductive plate 120A has the same shape as the
second type of conductive plate 120B, except that the left and
right sides thereof are inverted compared to the second type of
conductive plate 1208, the following description will focus on the
first type of conductive plate.
[0114] The conductive plate 120A according to the embodiment may
have an open annular planar shape having two end portions 120T_M
and 120T_R in order to form one turn of the secondary coil unit. In
this specification including FIG. 5, each of the conductive plates
120A and 120B is illustrated as having an open track shape centered
on a track-shaped hollow portion HC, but this is merely given by
way of example. The planar shape may be an open circular/elliptical
annular shape or an open polygonal annular shape.
[0115] For example, the first type of conductive plate 120A may
have a "q"-shaped planar shape. In addition, the second type of
conductive plate 120B, which is bilaterally symmetrical with the
first type of conductive plate 120A, may have a "p"-shaped planar
shape. Here, in the first type of conductive plate 120A, since the
first end portion 120T_M is connected to the ground, it may be
referred to as a ground end portion, and since the second end
portion 120T_R is connected to one signal line, it may be referred
to as a first signal end portion. Similarly, the second type of
conductive plate 121 may also have one ground end portion 120T M'
and one signal end portion 120T L. The signal end portion 120T_L
may be located opposite the first signal end portion 120T R, and
may be referred to as a second signal end portion.
[0116] Therefore, when four conductive plates are used for one coil
part constituting the secondary coil unit 120 and 130, e.g. the
upper coil part 121, a total of four ground end portions, two first
signal end portions, and two second signal end portions are
provided. The four ground end portions, the two first signal end
portions, and the two second signal end portions may at least
partially overlap each other in the vertical direction, or may be
aligned with each other in the vertical direction.
[0117] In this case, the two first signal end portions, the four
ground end portions, and the two second signal end portions may be
electrically connected to each other via the engaging parts 130,
but the remaining portions actually constituting the turns may be
insulated from each other so as not to be in direct contact with
each other.
[0118] In addition, each end portion may have therein a
through-hole H through which the engaging part 130 passes. Although
it is illustrated in FIG. 5 that one hole H having a rectangular
planar shape is formed in each end portion, the number and position
of holes may vary.
[0119] FIG. 6 is a view showing engagement of the conductive plates
according to an embodiment of the present disclosure.
[0120] Referring to FIG. 6, the secondary coil unit according to
the embodiment may be composed of a total of sixteen conductive
plates. In this case, the first type of conductive plates 120A and
the second type of conductive plates 1208 may be alternately
stacked in the vertical direction. Further, four conductive plates
located at the upper position may form one group to constitute the
upper coil part 121, eight conductive plates located at the middle
position may form another group to constitute the middle coil part
123, and four conductive plates located at the lower position may
form still another group to constitute the lower coil part 125. As
illustrated, the upper coil part 121, the middle coil part 123, and
the lower coil part 125 may overlap each other in the vertical
direction in the state of being spaced a predetermined distance
apart from each other. The spacing distance may vary depending on
the heights of the upper connection part 112 and the lower
connection part 114.
[0121] The conductive plates may be fixed to and electrically
connected to each other through a soldering method. In order to
realize soldering, metal bars 131, 132 and 133 may be inserted
through the respective holes H in the conductive plates. In some
embodiments, bus bars BB, which are electrically connected to the
metal bars 131, 132 and 133 or through which the respective metal
bars 131, 132 and 133 are inserted, may be further provided. When
the transformer 100 is mounted onto a substrate, the bus bars BB
may serve as electrical paths with the secondary coil and may also
serve to fix the transformer 100 onto the substrate. In FIG. 6, the
bus bars BB are disposed between the upper coil part 121 and the
middle coil part 123 and between the middle coil part 123 and the
lower coil part 125 in the thickness direction, but this is merely
given by way of example. The bus bars BB may be disposed on the
upper coil part 121 or under the lower coil part 125 in the
thickness direction depending on the arrangement relationship with
the substrate (not shown).
[0122] Meanwhile, in the embodiments described above, the
conductive plates located at the outermost positions in the
thickness direction, e.g. the conductive plate located at the
uppermost position in the upper coil part 121 and the conductive
plate located at the lowermost position in the lower coil part 125,
are spaced apart from the core part 140 by the fixing portions
111B_PT, 111C_PT and 111D_CM or the top portion 111A_T of the
bobbin 110. Unlike this, according to another embodiment of the
present disclosure, a heat conduction element may be disposed
between each of the conductive plates located at the outermost
positions in the thickness direction and the core part. The heat
conduction element may be in contact with one surface of each of
the conductive plates located at the outermost positions in the
thickness direction and one surface of the core part that faces the
one surface of the conductive plate. This will be described with
reference to FIG. 7.
[0123] FIG. 7 is a cross-sectional view showing an example of a
bobbin structure to which a heat dissipation unit according to
another embodiment of the present disclosure is applied. In FIG. 7,
the bobbin 110 may have any of the bobbin structures shown in FIGS.
3A to 3J. In addition, in FIG. 7, a configuration in which the
electric wires 161 and 162 constituting the primary coil unit are
wound is illustrated.
[0124] Referring to FIG. 7, a heat dissipation unit HD (e.g. a heat
dissipation sheet) having excellent heat conductivity may be
disposed between the conductive plate located at the outermost
position in the thickness direction, e.g. the upper surface 121TS
of the conductive plate disposed at the uppermost position in the
upper coil part 121, and the lower surface 141BS of the upper core
141, which faces the upper surface 121TS. Here, the upper surface
of the heat dissipation unit HD is in contact with the lower
surface 141BS of the upper core 141, and the lower surface of the
heat dissipation unit HD is in contact with the upper surface 121TS
of the conductive plate disposed at the uppermost position. Due
thereto, heat generated from the upper coil part 121 may be quickly
transferred to the upper core 141. This configuration may be
identically applied to the lower coil part 125 and the lower core
142.
[0125] Of course, when the transformer operates, the largest amount
of heat is generated near the central leg of the core part 140.
When the temperature of the core part 140 is higher, the heat from
the core part 140 is temporarily transferred to the secondary coil
unit via the heat dissipation unit HD more quickly than when the
heat dissipation unit HD is absent. However, since the core part
140 functions to primarily dissipate heat to the bracket or the
substrate, the heat from the secondary coil unit may be quickly
dissipated via the core part 140.
[0126] Hereinafter, a transformer according to still another
embodiment of the present disclosure will be described in more
detail with reference to FIGS. 8 to 17.
[0127] FIG. 8 is a perspective view showing an example of a
transformer 1100 according to an embodiment of the present
disclosure, and FIG. 9 is an exploded perspective view showing an
example of a clip-coupled transformer according to still another
embodiment of the present disclosure.
[0128] Referring to FIGS. 8 and 9, a clip-coupled transformer 1100
according to an embodiment of the present disclosure may include a
bobbin 1110, a plurality of conductive plates 1120 inserted into
the bobbin 1110, a plurality of engaging parts 1130 electrically
connecting the plurality of conductive plates 1120 so as to
constitute a secondary coil unit together with the plurality of
conductive plates 1120 in an integral form, and a core part 1140
coupled to the outer side of the bobbin 1110 so as to surround at
least a portion of the bobbin 1110.
[0129] Here, the transformer 1100 according to the embodiment may
further include a conductive wire wound on the bobbin 1110 to
constitute a primary coil unit, but an illustration thereof is
omitted in the drawings of this specification. The primary coil
unit (not shown) may take a multiple-winding form, in which a rigid
conductive metal, e.g. a copper conductive wire, is wound several
times.
[0130] The secondary coil unit 1120 and 1130 may transform and
output a power signal received from the primary coil unit (not
shown). In FIG. 8, the secondary coil unit 1120 and 1130 may be
configured such that a total of eight conductive plates is stacked
in the thickness direction (e.g. the z-axis direction). Each
conductive plate may correspond to one turn in the secondary coil
unit. That is, when eight conductive plates are used, the number of
turns in the secondary coil unit may be eight, but this is merely
given by way of example. A greater or smaller number of conductive
plates may be used. In this case, the number of turns in the
secondary coil unit may be proportional to the number of conductive
plates.
[0131] For example, each of the plurality of conductive plates 1120
may be inserted into the bobbin 1110 in the x-axis direction.
[0132] The plurality of conductive plates 1120 may be electrically
insulated from each other by insulation materials, except for
electrical connection via the engaging parts 1130. For example, an
insulation film may be disposed between adjacent conductive plates
among the plurality of conductive plates in order to electrically
insulate the conductive plates from each other. The insulation film
may include components such as ketone and polyimide, without being
necessarily limited thereto. In addition, the plurality of
conductive plates 1120 may be spaced apart from each other in the
thickness direction due to the thickness of washers 1132 of the
engaging parts 1130 to be described later, thereby being insulated
from each other. This will be described later with reference to
FIG. 17.
[0133] In addition, the plurality of conductive plates 1120 may
include a conductive metal, e.g. copper, without being necessarily
limited thereto. For example, the plurality of conductive plates
may include aluminum. When aluminum is used instead of copper, the
thickness of each conductive plate may be approximately 60% greater
than that when copper is used.
[0134] The bobbin 1110 may have a shape suitable for insulating the
conductive wires (not shown) constituting the primary coil unit,
the plurality of conductive plates 1120 constituting the secondary
coil unit, and the core part 1140 from each other while
accommodating or fixing at least a portion of each of the
components 1120 and 1140.
[0135] The bobbin 1110 may include an insulation material, e.g. a
resin material, and may be produced through a molding method. The
more concrete shape of the bobbin 1110 will be described later with
reference to FIG. 10.
[0136] The engaging part 1130 may include a bolt 1131, a washer
1132, and a nut 1132. The bolt 1131 may penetrate all of the
plurality of conductive plates 1120 constituting the secondary coil
unit in the vertical direction (e.g. the z-axis direction), and the
washers 1132 may be disposed between the conductive plates that are
located adjacent to each other and have the same shape. In
addition, the nut 1133 may serve to fix the conductive plates 1120
such that a predetermined number (e.g. four) of conductive plates
1120 are in close contact with each other. For example, a
predetermined number of conductive plates may be fixed between one
nut 1133 and another nut 1133 or between the head of the bolt 1131
and the nut 1133.
[0137] The core part 1140, which has the characteristics of a
magnetic circuit, may serve as a path for magnetic flux. The core
part may include an upper core 1141 coupled from the upper side and
a lower core 1142 coupled from the lower side. The two cores 1141
and 1142 may have shapes that are vertically symmetrical with each
other, or may have shapes that are vertically asymmetrical with
each other. The core part 1140 may include a magnetic material,
e.g. iron or ferrite, without being necessarily limited thereto.
The concrete shape of the core part 1140 will be described later
with reference to FIG. 11.
[0138] FIGS. 10A and 10B are respectively a side view and a front
view of a bobbin according to still another embodiment of the
present disclosure.
[0139] Referring to FIGS. 10A and 10B, the bobbin 1110 may include
a first plate 1111, a second plate 1112, a third plate 1113, a
fourth plate 1114, a connection part 1115 connecting the second
plate 1112 and the third plate 1113, sidewall parts 1116U and
1116L, and a winding-fixing part 1117. Each of the plates 1111,
1112, 1113 and 1114 may have an annular planar shape. The plates
1111, 1112, 1113 and 1114 and the connection part 1115 may be
aligned in the vertical direction about a through-hole TH when
viewed in plan. Further, the inner surface of the connection part
1115 may define the sidewall of the through-hole TH.
[0140] The sidewall parts 1116U and 1116L may include an upper
sidewall 1116U disposed between the first plate 1111 and the second
plate 1112 and a lower sidewall 1116L disposed between the third
plate 1113 and the fourth plate 1114. Each of the sidewalls 1116U
and 1116L may have an arc-shaped planar shape. A first opening OP1
may be formed in the portion between the first plate 1111 and the
second plate 1112 in which the upper sidewall 1116U is not
disposed, and a second opening OP2 may be formed in the portion
between the third plate 1113 and the fourth plate 114 in which the
lower sidewall 1116L is not disposed. An upper coil part 1120T,
which will be described later, may be inserted through the first
opening OP1, and a lower coil part 1120U, which will be described
later, may be inserted through the second opening OP2. In other
words, the upper coil part 1120T may be received in the receiving
hole defined by the first plate 1111, the second plate 1112, and
the upper sidewall 1116U, and the lower coil part 1120U may be
received in the receiving hole defined by the third plate 1113, the
fourth plate 1114, and the lower sidewall 1116L.
[0141] The conductive wire (not shown) constituting the primary
coil unit may be wound around the outer circumferential surface of
the connection part 1115 in the space between the second plate 1112
and the third plate 1113. The winding-fixing part 1117 may include
two holes 1117H, and one end and the other end of the conductive
wire (not shown) constituting the primary coil unit may be fixedly
fitted into the respective holes 1117H.
[0142] In addition, one or more protruding portions 1118 may be
disposed on the upper surface of the first plate 1111 and the lower
surface of the fourth plate 1114 in order to guide the coupling
position of the core part 1140 and to prevent the core part 1140
from being rotated about the through-hole TH when the core part
1140 is coupled.
[0143] Next, the configuration of the core part 140 will be
described with reference to FIGS. 11A and 11B. FIG. 11A is a plan
view of the core part according to the embodiment, and FIG. 11B is
a perspective view of the external appearance of an example of the
lower core. Referring to FIG. 11A, the core part 1140 may have a
sandglass-shaped planar shape. The core part 1140 having such a
planar shape may be referred to as a "pq"-type core. Due to this
planar shape, the core part 1140 may have a short axis and a long
axis. For example, in FIG. 11A, the short-axis direction may
correspond to the x-axis direction, and the long-axis direction may
correspond to the y-axis direction.
[0144] Any one (here, the lower core 1142) of the cores
constituting the core part 1140 may include a central portion
1142_1 having a circular column shape and side portions 1142_2
disposed at both sides that face each other around the central
portion 1142_1. In this case, in order to couple the lower core
1142 to the bobbin 1110 in the form of surrounding the bobbin 1110,
a receiving hole may be formed in a toroidal shape between the
inner circumferential surfaces of the side portions 1142_2 and the
outer circumferential surface of the central portion 1142_1, and
may correspond to the size of the bobbin 1110. Meanwhile, the
central portion 1142_1 may be inserted into the through-hole TH in
the bobbin 110. Meanwhile, the central portion 1142_1 may be
referred to as a "central leg". When coupled to the bobbin 1110,
the central leg (not shown) of the upper core 1141 and the central
leg 1142_1 of the lower core 1142 may come into contact with each
other, or may be spaced apart from each other by a predetermined
distance (e.g. 100 .mu.m).
[0145] Next, the configuration of a plurality of conductive plates
constituting the secondary coil unit will be described with
reference to FIGS. 12A to 14C.
[0146] FIGS. 12A and 12B show the respective planar shapes of two
types of conductive plates according to still another embodiment.
In addition, FIG. 13A is an exploded perspective view showing the
configuration of a secondary coil unit according to still another
embodiment, FIG. 13B is a perspective view showing engagement of
the plurality of conductive plates, and FIG. 13C is a plan view of
the plurality of conductive plates shown in FIG. 13B. In addition,
FIGS. 14A and 14B show the respective planar shapes of two types of
conductive plates according to still another embodiment, and FIG.
14C is a plan view showing engagement of the conductive plates
shown in FIGS. 14A and 14B.
[0147] First, referring to FIGS. 12A and 12B, two types of
conductive plates 1121 and 1122 having different planar shapes are
illustrated. Since the first type of conductive plate 1121 has the
same configuration as the second type of conductive plate 1122,
except that the left and right sides thereof are inverted compared
to the second type of conductive plate 1122, the following
description will focus on the first type of conductive plate 1121
shown in FIG. 12A.
[0148] The conductive plate 1121 according to the embodiment may
have an open annular planar shape having two end portions 1121D and
1121E in order to form one turn of the secondary coil unit.
Although the conductive plate is illustrated as having a circular
annular shape in still another embodiment including FIG. 12A, this
is merely given by way of example. The planar shape may be an open
circular/elliptical annular shape, an open polygonal annular shape,
or an open track-type annular shape.
[0149] For example, the first type of conductive plate 1121 may
actually form one turn of the secondary coil unit, and may include
a coil portion 1121A, which has an open annular planar shape
centered on a hollow portion HC, a first end portion 1121D, a
second end portion 1121E, a first connection portion 1121B, which
connects one end of the coil portion 1121A and the first end
portion 1121D and extends in one axis direction (e.g. the X-axis
direction), and a second connection portion 1121C, which connects
the other end of the coil portion 1121A and the second end portion
1121E and extends in one axis direction (i.e. the x-axis).
Therefore, the two connection portions 1121B and 1121C extend in a
direction parallel to each other when viewed in plan.
[0150] The first type of conductive plate 1121 may have a
"q"-shaped planar shape due to the coil portion 1121A, the first
connection portion 1121B, and the second connection portion 1121C.
In addition, the second type of conductive plate 1122, which is
bilaterally symmetrical with the first type of conductive plate
1121, may have a "p"-shaped planar shape. Here, in the first type
of conductive plate 1121, since the first end portion 1121D is
connected to the ground, it may be referred to as a ground end
portion, and since the second end portion 1121E is connected to one
signal line, it may be referred to as a first signal end portion.
Similarly, the second type of conductive plate 1121 may also have
one ground end portion and one signal end portion. The signal end
portion may be located opposite the first signal end portion 1121E,
and may be referred to as a second signal end portion.
[0151] Therefore, when four conductive plates are used, a total of
four ground end portions, two first signal end portions, and two
second signal end portions are provided. The four ground end
portions, the two first signal end portions, and the two second
signal end portions may at least partially overlap each other in
the vertical direction, or may be aligned with each other in the
vertical direction.
[0152] The two first signal end portions, the four ground end
portions, and the two second signal end portions may be
electrically connected to each other via the engaging parts 1130,
but the coil portion 1121A may be insulated from another coil
portion so as not to be in direct contact therewith.
[0153] In addition, the end portions may have therein through-holes
H1 and H2 through which the bolts 1131 of the engaging parts 1130
pass. The number and position of holes formed in each end portion
may vary.
[0154] Meanwhile, as shown in FIG. 12B, protruding portions PT are
provided on the outer periphery of the coil portion 1121A. When
coupled to the bobbin 1110, the protruding portions may come into
contact with the edges of the sidewall parts 1116U and 1116L, so
the position at which the coil portion is fixed to the bobbin 1110
may be guided.
[0155] Next, referring to FIGS. 13A to 13C, the secondary coil unit
according to still another embodiment may be composed of a total of
eight conductive plates. In this case, the first type of conductive
plates 1121 and the second type of conductive plates 1122 may be
alternately stacked in the vertical direction. Further, four
conductive plates located at the upper position may form one group
to constitute the upper coil part 1120T, and four conductive plates
located at the lower position may form another group to constitute
the lower coil part 1120U. As illustrated, the upper coil part
1120T and the lower coil part 1120U may overlap each other in the
vertical direction in the state of being spaced a predetermined
distance apart from each other. The spacing distance may vary
depending on the engagement relationship with the engaging parts
1130. For example, the spacing distance may be adjusted depending
on the distance between the nuts 133 fastened to the bolt 1131.
When the upper coil part 1120T and the lower coil part 1120U are
received in the bobbin 1110, the primary coil unit (not shown) may
be disposed between the upper coil part 1120T and the lower coil
part 1120U.
[0156] In the above-described embodiment, the two connection
portions 1121B and 1121C of the conductive plates 1121 and 1122
extend parallel to each other in one direction (e.g. the X-axis)
perpendicular to the horizontal direction (e.g. the Y-axis). Unlike
this, according to another aspect of the present embodiment, the
two connection portions may extend so as to have a predetermined
inclination (tilt) at a predetermined angle when viewed in plan,
rather than being perpendicular to the horizontal direction.
[0157] This will be described with reference to FIGS. 14A to 14F.
The following description will focus on differences from the
conductive plates 1121 and 1122 shown in FIGS. 12A and 12B.
[0158] First, a conductive plate according to another aspect of the
present embodiment will be described with reference to FIGS. 14A to
14C. FIG. 14A shows a first type of conductive plate 1121'. The
first type of conductive plate 121' according to another aspect may
have an open annular planar shape having two end portions 1121D'
and 1121E' in order to form one turn of the secondary coil
unit.
[0159] For example, the first type of conductive plate 1121' may
actually form one turn of the secondary coil unit, and may include
a coil portion 1121A', which has an open annular planar shape
centered on a hollow portion HC', a first end portion 1121D', a
second end portion 1121E', a first connection portion 1121B', which
connects one end of the coil portion 1121A' and the first end
portion 1121D' and extends in one direction, and a second
connection portion 1121C', which connects the other end of the coil
portion 1121A' and the second end portion 1121E' and extends in one
direction. Therefore, the two connection portions 1121B' and 1121C'
extend in a direction parallel to each other when viewed in
plan.
[0160] In this case, unlike the configuration shown in FIGS. 12A
and 12B, the two connection portions 1121B' and 1121C' may extend
in a direction different from the front direction of the bobbin
(e.g. the x-axis direction). For example, the two connection
portions 1121B' and 1121C' may extend in a direction inclined at a
predetermined angle .theta. with respect to the horizontal
direction (e.g. the y-axis direction), rather than being
perpendicular to the horizontal direction.
[0161] Here, the direction in which the connection portions 1121B'
and 1121C' extend may be a direction in which a straight line
included in any one of the edge regions of the connection portions
that include straight lines extends, or may be a direction in which
sides that are adjacent and parallel to each other among the edges
of the first connection portion 1121B' and the second connection
portion 1121C' (e.g. the right side of the first connection portion
and the left side of the second connection portion) extend.
[0162] Further, the predetermined angle .theta. may be an angle
formed by the horizontal direction and the extension direction, or
may be an angle formed by a line connecting the center of the
hollow portion HC' and the center of any one through-hole (e.g.
H2') and the horizontal direction. Further, when the direction in
which the first connection portion 1121B' extends and the direction
in which the second connection portion 1121C' extends are not
parallel to each other, the predetermined angle .theta. may
represent the direction in which any one of the first connection
portion 1121B' and the second connection portion 1121C'
extends.
[0163] For example, the predetermined angle .theta. may be greater
than 0 degrees and less than 90 degrees, preferably 87 degrees or
less, and more preferably about 60 degrees.
[0164] The reason for setting this range of the angle .theta. is to
maximize the planar area of the coil portion 1121A' and to reduce
the curvatures of the portions at which the curvatures change
between the coil portion 1121A' and the connection portions 1121B'
and 1121C' (or the boundary portions between the coil portion and
the extending portions: R1, R2, R3 and R3). The large planar area
of the coil portion 121A means that the capacity and efficiency are
high compared to the size of the transformer. The small curvatures
of the portions R1, R2, R3 and R4 at which the curvatures change
between the coil portion 1121A' and the connection portions 1121B'
and 1121C' mean that the occurrence of a current concentration
phenomenon may be reduced at the corresponding portions R1, R2, R3
and R4.
[0165] In more detail, the coil portion 1121A' has an inner
diameter curvature corresponding to the curvature of the hollow
portion HC' and an outer diameter curvature that is smaller than
the inner diameter curvature. The boundary portions R1, R2, R3 and
R4 with the connection portions 1121B' and 1121C' have curvatures
different from the inner diameter curvature or the outer diameter
curvature. Here, any one of the four boundary portions R1, R2, R3
and R4 may have a curvature larger than the curvatures of the
remaining ones of the boundary portions. For example, the fourth
boundary portion R4 between the outer edge of the coil portion
1121A' and the second extending portion 1121C' may have a larger
curvature than the first boundary portion R1, the second boundary
portion R2, and the third boundary portion R3.
[0166] FIG. 14B shows the second type of conductive plate 1122'.
Since the second type of conductive plate 1122' and the first type
of conductive plate 1121' have the same structure, except that they
are bilaterally symmetrical with each other, a duplicate
description thereof will be omitted.
[0167] Meanwhile, when the conductive plates 1121' and 1122'
according to another aspect of the present embodiment have the same
range of angle .theta. as described above and the length H1 thereof
in the X-axis direction is 48.47 mm, the width w1 of the first
extending portion 1121B' may be 10 mm, and the height H2 of the
second end portion 1121E may be 10 mm, but this is merely given by
way of example. The sizes of the conductive plates 1121' and 1122'
are not limited thereto.
[0168] Next, referring to FIGS. 14D to 14F, a first type of
conductive plate 1121'' and a second type of conductive plate
1122'' according to still another aspect are illustrated. Since the
first type of conductive plate 1121'' and the second type of
conductive plate 1122'' have substantially the same configuration,
except that they are bilaterally symmetrical with each other, the
following description will focus on the first type of conductive
plate 1121''.
[0169] The first type of conductive plate 1121'' according to still
another aspect may have an open annular planar shape having two end
portions 1121D'' and 1121E'' in order to form one turn of the
secondary coil unit. The first end portion 1121D'' may have therein
a first through-hole H1'', and the second end portion 1121E'' may
have therein a second through-hole H2''.
[0170] For example, the first type of conductive plate 1121'' may
actually form one turn of the secondary coil unit, and may include
a coil portion 1121A'', which has an open annular planar shape
centered on a hollow portion HC'', a first end portion 1121D'', a
second end portion 1121E'', a first connection portion 1121B'',
which connects one end of the coil portion 1121A'' and the first
end portion 1121D'' and extends in the vertical direction (e.g. the
x-axis direction), and a second connection portion 11210'', which
connects the other end of the coil portion 1121A'' and the second
end portion 1121E'' and extends in one direction.
[0171] The first connection portion 1121B'' and the second
connection portion 11210'' are spaced apart from each other when
viewed in plan, and the spacing distance D1 may change in the
extension direction. However, the spacing distance D1 is preferably
equal to or greater than the thickness of each of the conductive
plates 1121'' and 1122''.
[0172] Unlike the configurations shown in FIGS. 12A, 12B, and 14A
to 14C, one 1121C'' of the two connection portions 1121B'' and
11210'' may extend in a direction different from the front
direction (e.g. the x-axis direction) of the bobbin. In other
words, the direction in which the second connection portion 11210''
extends may form a predetermined angle .theta.' with the direction
in which the first connection portion 1121B'' extends.
[0173] Here, the direction in which the first connection portion
1121B'' extends may be defined as a direction that is oriented from
the center HCC'' of the hollow portion HC'' toward the center H1C''
of the first through-hole H1'', and the direction in which the
second connection portion 11210'' extends may be defined as a
direction that is oriented from the center HCC'' of the hollow
portion HC'' toward the center H2C'' of the second through-hole
H2''. Unlike this, the direction in which the second connection
portion 11210'' extends may be defined as a direction that is
oriented from the center H2C'' of the second through-hole H2''
toward an edge H2''-1 of the second end portion 1121E'' located
therebelow in the vertical direction, rather than the direction
that is oriented from the center HCC'' of the hollow portion HC''
toward the center H2C'' of the second through-hole H2''.
[0174] Hereinafter, the condition of the angle .theta.' formed by
the direction in which the second connection portion 11210''
extends and the direction in which the first connection portion
1121B'' extends will be described with reference to FIG. 14F.
[0175] As shown in FIG. 14F, when the center HCC'' of the hollow
portion HC'', the center H1C'' of the first through-hole H1'', and
the center H2C'' of the second through-hole H2'' are connected, a
right triangle is formed. In the right triangle, each of two angles
that are not a right angle is an acute angle, and the sum of the
two angles is 90 degrees at all times. Therefore, the angle
.theta.' needs to satisfy the range of "0<.theta.'<90".
[0176] However, the maximum size of the conductive plate is limited
by the size of the entrance of the core 140, i.e. the shortest
distance D2 between the side portions 1142_2 facing each other. In
other words, the size D2 of the entrance of the core needs to be
equal to or greater than the sum of the width D3 of the three
connection portions located on the same line as the entrance of the
core, the distance D1 between adjacent connection portions, and the
tolerance D4 between the conductive plate and the two side portions
of the core (i.e. 3*D3+2*D1+2*D4.ltoreq.D2).
[0177] Here, assuming that the minimum value of the tolerance D4 is
0.1 mm (i.e. 0.1 mm.ltoreq.D4) and the core is a ferrite core of
PQ40.5/30.3/28A standard, the minimum value of D2 is 27.8 mm. In
addition, assuming that the thickness of one conductive plate is 1
mm, the distance D1 between adjacent connection portions is 1 mm.
Under these assumptions, if the three connection portions have the
same width D3, the width D3 of each connection portion is 8.5 mm
((27.8-2-0.2)/3).
[0178] Further, according to the trigonometric principle, tan
.theta.'=S1/S2, and so the angle .theta.' is as follows:
.theta.'=tan-1(S1/S2). In this case, if S1 is a constant, the value
of angle .theta.' may vary depending on the length of S2.
[0179] Of course, the maximum value of .theta.' is determined to be
less than 90 degrees, but the minimum value in actual
implementation may be obtained as follows.
[0180] Assuming that the width D3 of each connection portion is 1
mm, S2=D3+D1, and so S2 is 2 mm. Since the length of S1 needs to be
greater than the outer radius of the coil portion 1121A'' and the
vertical length of the first connection portion 1121B'', the
minimum value of S1 becomes 38.7 mm.
[0181] That is, since .theta.'=tan-1 (2/38.7) and the value of tan
.theta.' is 0.0524 at the angle of about 3.degree., the minimum
angle .theta.' may become 3.degree.. As a result, .theta.' may be
"3.degree.<.theta.'<90.degree.", preferably about
30.degree..
[0182] Meanwhile, according to another aspect of the present
embodiment, the above-mentioned right triangle may be replaced with
a right triangle formed by connecting the center HCC'' of the
hollow portion HC'', an edge H1C''-1 of the first end portion
1121D'' that is located vertically below the center H1C'' of the
first through-hole H1'', and an edge H2''-1 of the second end
portion 1121E'' that is located vertically below the center H2C''
of the second through-hole H2''.
[0183] FIG. 15 is a view showing engagement of conductive plates
according to still another embodiment of the present disclosure. In
FIG. 15, for convenience of description, among a plurality of
conductive plates constituting the secondary coil unit, only a
first type of conductive plate 1121 located at the uppermost
position and a second type of conductive plate 1122 disposed
therebelow are illustrated.
[0184] Referring to FIG. 15, the first type of conductive plate
1121 and the second type of conductive plate 1121 are engaged by a
bolt 1131C that passes through through-holes H1 formed in ground
end portions thereof without a washer. Unlike this, a washer 1132A
is disposed between a signal end portion of each of the first type
of conductive plate and the second type of conductive plate and a
signal end portion of the same type of conductive plate (not shown)
located therebelow. In this case, the thickness of the washer may
be the same as the thickness of the conductive plate. Due to this
configuration, the ground end portions of the plurality of
conductive plates constituting the secondary coil unit form a
closed loop via the bolt 1131C, and the signal end portions thereof
form a closed loop via the bolt 1131A while maintaining the
distance therebetween via the washer 1132A.
[0185] FIGS. 16A and 16B are views showing engagement of conductive
plates and a bobbin according to still another embodiment of the
present disclosure.
[0186] Referring to FIG. 16A, an upper coil part 1120T may be
inserted into a bobbin through a first opening OP1, and a lower
coil part 1120U may be inserted into the bobbin through a second
opening OP2. Here, protruding portions PT formed at the side
surfaces of the coil parts 1120T and 1120U may serve to guide the
positions at which the coil parts 1120T and 1120U are received and
fixed in the bobbin and to prevent the coil parts 1120T and 1120U
from moving or rotating about a through-hole TH after insertion.
For example, when the upper coil part 1120T is inserted into the
bobbin 1110 through the first opening OP1, the protruding portions
PT of the upper coil part 1120T come into contact with both edges
of an upper sidewall 1116U defining the first opening OP1.
Accordingly, after the protruding portions PT of the upper coil
part 1120T come into contact with the edges of the upper sidewall
1116U, the upper coil part 120T is not capable of being inserted
more deeply, and is prevented from being rotated in the inserted
state.
[0187] Next, FIG. 16B shows a case to which the conductive plates
described with reference to FIGS. 16D to 16F are applied. Similar
to the case of FIG. 16A, an upper coil part 1120T'' is inserted
into the bobbin 1110 through the first opening OP1, and a lower
coil part 1120U'' is inserted into the bobbin 1110 through the
second opening OP2.
[0188] However, the conductive plates may be fixed to and
electrically connected to each other through a soldering method,
rather than using the bolt 1131, the washer 1132, and the nut 1133.
In order to realize soldering, soldering pins 1134 may be inserted
through first holes H1'' and second holes H2'' overlapping each
other in the thickness direction. In some embodiments, terminals
TM, which are electrically connected to the soldering pins 134 or
through which the soldering pins 1134 are inserted, may be further
provided. When the transformer 1100 is mounted onto a substrate,
the terminals TM may serve as electrical paths with the secondary
coil and may also serve to fix the transformer 1100 onto the
substrate. In FIG. 16B, the terminals TM are disposed between the
upper coil part 1120T'' and the lower coil part 120U'' in the
thickness direction, but this is merely given by way of example.
The terminals TM may be disposed on the upper coil part 1120T'' or
under the lower coil part 1120U'' in the thickness direction
depending on the arrangement relationship with the substrate (not
shown). Even if the conductive plates described with reference to
FIGS. 14D to 14F are applied, the remaining components such as the
bobbin 1110 and the core 1140 may be applied in the same manner as
described above.
[0189] Meanwhile, according to still another embodiment of the
present disclosure, the spacing distance between conductive plates
may be adjusted depending on the thickness of a washer. This will
be described with reference to FIG. 17. FIG. 17 shows an example of
engagement of conductive plates according to still another
embodiment of the present disclosure.
[0190] In the above-described embodiments, it has been described
that the thickness of the washer and the thickness of the
conductive plate are the same. In this case, since conductive
plates constituting one group are in close contact with each other,
a separate insulation member such as an insulation film is required
in order to insulate the conductive plates from each other.
However, as shown in FIG. 17, when the thickness T1 of the washer
1131A' is greater than the thickness T2 of each of the conductive
plates 1121-1, 1121-2, 1122-1 and 1122-2, at least some of the
conductive plates that are adjacent to each other (e.g. 1122-1 and
1121-2) are not in close contact with each other and are spaced
apart from each other in the thickness direction, so an insulation
member may be omitted between the corresponding conductive
plates.
[0191] Although only a limited number of embodiments have been
described above, various other embodiments are possible. The
technical contents of the above-described embodiments may be
combined into various forms as long as they are not incompatible
with one another, and thus may be implemented in new
embodiments.
[0192] For example, in still another embodiment, the first signal
end portion, the ground end portion, and the second signal end
portion are illustrated as extending in the same direction (e.g.
the x-axis direction) to be exposed together from one surface (e.g.
front surface) of the bobbin 1110, but this is merely given by way
of example. At least some of the first signal end portion, the
ground end portion, and the second signal end portion may extend in
a direction different from the direction in which the remaining end
portions extend, and may be exposed from the bobbin in a direction
different from the direction in which the remaining end portions
are exposed.
[0193] In addition, although the conductive plates have been
described as being engaged with and electrically connected to each
other via the engaging parts including the bolts, the washers and
the nuts, the conductive plates may be engaged with and
electrically connected to each other through a soldering
method.
[0194] Further, the transformers 100 and 1100 according to the
above-described embodiments may be used for an instrument
transformer, an AC-calculating board, a DC-DC converter, a step-up
transformer, a step-down transformer, etc.
[0195] It will be apparent to those skilled in the art that various
changes in form and details may be made without departing from the
spirit and essential characteristics of the disclosure set forth
herein. Accordingly, the above detailed description is not intended
to be construed to limit the disclosure in all aspects and to be
considered by way of example. The scope of the disclosure should be
determined by reasonable interpretation of the appended claims and
all equivalent modifications made without departing from the
disclosure should be included in the following claims.
* * * * *